Flashlight construction



Dec. 31, 1957 w. c. MOORE FLASI-LIGHIT CONSTRUCTION Filed Feb. 24, 1955 INVENTOR. WILL/17M =C. MoaRE w QM;

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a 2,818,499 l Patented Dec. 3 1957 FLASHLIGHT CONSTRUCTION William C. Moore, Bainbridge, N. Y., assignor to Welch Allyn, Inc., Skaneateles Falls, N. Y., a corporation of New York Application February 24, 1955, Serial No; 490,239

6 Claims. (Cl! 240-1058) This invention relates generally to electric hand lamps, and has specific reference to an improved construction for hand lamps of the flashlight type. The invention is particularly well adapted for use'in connection with small pocket or pen type flashlights, although: it need. not be limited to suchuse.

Broadly stated, the invention contemplates the provision of a flashlight which .will operate in an improved manner and at the same time be eflicient' and economical.

to manufacture. This. is accomplished by providing an improved overall construction forthe flashlight including greatly simplified control switch and lampv bulb. holder assemblies. The control switch assembly includes: a positive action switch and a novel holding and release mechanism therefor, the entire assembly being of simple,

compact construction. The lamp bulb holder assembly comprises a simplified, low-cost holder; to support the bulb, and a novel current conducting means associated with the holder which servesv to establish electrical contact between one of the bulb terminals and the remainder of the flashlight circuit.

The primary object of the present invention, therefore,

is to provide a flashlight construction having'improved operating characteristics.

Another important object of the invention is to provide a flashlight construction which lends itself to an eflicient and economical manner of manufacture.

A further important object of the invention is to provide a flashlight construction which is strong and durable, being capable of reliable performance over a long period of time.

A more specific object of the invention is to provide a flashlight construction having a quick operating, posi-- tive action control switch.

Another specific object of the invention is to provide a flashlight construction having a simplified, inexpensive lamp bulb holder.

Other objects and advantages of the: invention will become apparent from the following detailed description read inconjunction with the accompanying drawings wherein like reference numbers designate corresponding parts in all the views.

In the drawings:

Figure l is a longitudinalrsectional' view of a flashlight embodying the invention, the control switch being shown in open position;

Figure 2 is a fragmentary sectional. view corresponding to Figure 1, the control switch being shown in closed" position;

Figure 3 is a transverse sectional view taken along line 33 of Figure 1 showing the switch holding and release mechanism when the switch is in open position;

Figure 4 is a transverse sectional view corresponding,

to Figure 3 showing the switch, holding and releasemechanism when the switch is inv closed position; and

Figure 5 is a fragmentary perspective. view ofthelamp bulb holder. Having reference now to the drawings which illustrat a typical: embodiment of the invention for the purpose of disclosure, 10 generally indicates a pocket or pen type flashlight comprising a tubular body member or casing 11, a head 12. mounted on one end of the body member and a. control switch assembly 14 mounted on the other end of the body member. Member 11 is formed of metal or other suitable current conducting material, and is adapted to enclose one or more conventional dry cells 15, as shown. The head 12 is also formed of some suitable current conducting material and is secured to the body member as by threaded connection 17.

Head 12 is adapted to support and substantially enclose a lamp bulb 18' so that the central terminal 20 of the bulb engages. and makes electrical connection with the base terminal of one of the dry cells 15. In accordance with the invention, the bulb is held in position in thehead by means of a ring shaped bulb holder assembly 21, Figure 1, which frictionally engages the base of the bulb. This-assembly is comprised of a strip 22, Figure 5, of resilient material and a plurality of conducting elements 24 extending through the strip, the strip with the elements 24. assembled therein being bent into ring shape and positioned in the head between internal shoulders 25, 27.

Strip 22 is preferably formed of some material such as neoprene rubber or the like, while the conducting elements 24 are in the form of fine wire staples. The legs of the staples are passed through the strip and folded over, Figures 1 and 5, so that a portion of each staple is exposed on each side of the strip to establish an electrical connection between the threaded terminal 28 of the bulb and the head 12. As is best shown in Figure 5, the elements or staples 24 pass at regularly spaced intervals through the strip and are obliquely arranged with respect to the longitudinal axis thereof so that good contact between the staples and threaded bulb terminal 28 is. insured.

The bulb holder arranged above described permits the use of eflicient, low-cost production and assembly methods in the manufacture of the flashlight. Thus, bulb holder assemblies can be quickly and cheaply produced by attaching the staples 24 to long lengths of the resilient strip material with an automatic stapling machine or the like, and thereafter cutting the lengths up to form a large number of strips 22. A strip with the staples attached thereto can then be assembled in the head 12 by simply bending it into ring shape and pushing it into place between the shoulders 25, 27. In addition, since the bulb 18 is retained in the head by frictional engagement with the bulb holder assembly rather than by a threaded connection, it will be apparent that the bulb can also be rapidly assembled in the head by simply pushing it into operative position.

The control switch assembly 14 includes a housing 30 which is formed of metal or other suitable con-ducting material and is secured to the flashlight body member 11 as by the threaded connection 31. The inner and outer ends of housing 30 are bored at 32, 34 respectively, the bores being separated by a transverse wall 35 having a smaller, centrally disposed bore 37 therethrough. Mounted within the inner bore 32 are a pair of movable contact members 38, 40 which are movable longitudinally of the bore and are guided during such movement by a sleeve 41 and a retaining element 42. The sleeve and retaining element are formed of some suitable insulating material such as plastic, and the retaining element may be secured in position by frictional engagement with the bore wall, as shown, or may have threaded engagement therewith.

Contact 40 is in the form of a metal cup which receives one. end of. a compression spring 44 positioned within the bore 32. The opposite end of the spring is received in asecond metal cup 45 which bears against the central terminal 47 of one of the dry cells 15 thereby establishing an electrical connection between the cell and the contact 40. The spring 44 holds the 'dry cells in contact with one another and with the central terminal of the bulb, and also urges contact 40 outwardly, the latter being limited in its outward movement by a flange 48 on the cup which normally bears against the sleeve 41.

Contact 38 is mounted on the inner end of a metal plunger element which extends outwardly through bores 37, 34 and terminates in a plunger finger piece or cap 50. The portion of the plunger element between the contact and finger piece is in the form of a cylindrical shank, and that part 51 of the shank which is positioned inwardly of the transverse wall 35, within bore 32, has a larger diameter than that of the bore 37, while the remaining part 52 of the shank is of reduced diameter having a slidable fit in the bore 37. A compression spring 54- is positioned between the finger piece 50 and transverse wall 35 within the bore 34, the spring serving to normally hold the shank part 51 in engagement with the wall and thereby maintain contact 38 in spaced relation to contact 40 so that the control switch is normally in open position. In this position of the switch, the finger piece projects outwardly beyond the end of the switch housing 30, as shown in Figure 1.

To close the control switch, the finger piece is pushed inwardly against the resistance of spring 54 and this moves contact 38 into engagement with contact 40, Figure 2, completing the flashlight circuit from the central terminal 29 of the bulb, through the dry cells, contacts 33, 4t plunger element, switch housing 30, body member 11, head 12 and bulb holder assembly 21 to the threaded terminal 28 of the bulb. In this connection, it should be noted that when the finger piece is pushed inwardly as far as it will go, i. e. until spring 54 is compressed to its limit, Figure 2, contact 33 not only moves into engagement with contact 4d but pushes it inwardly as well. This causes spring 44 to be compressed so that it exerts increased force upon the cup 4 5 and dry cells 15, and thus insures good contact therebetween.

When the plunger element has been actuated as above described to close the control switch, it is maintained in switch closing position by means of a substantially U- shaped resilient clip or detcnt 5'5 of some suitable material such as spring steel. The egs or sides 57 of this clip are biased inwardly so that the free ends thereof tend to converge or move into close proximity with one another unless forcibly held apart. The clip is mounted in the control switch housing between the transverse wall 35 and sleeve 41, Figures 1 and 3, so that its sides are in engagement with the enlarged part 51 of the plunger shaft and are sprung outwardly into substantially parallel relationship thereby, see Figure 3. When the plunger element is moved inwardly to close the switch, the clip is held in fixed position so that the part 51 of the plunger shaft moves out of engagement with the clip sides. This permits the clip sides to spring inwardly against the smaller part 52 of the shaft and engage the shoulder between the shaft parts El, 52 thereby locking the switch in closed position, Figures 2 and 4.

The clip 55 is released from looking position by means of an independent cam actuator comprising a cam head having a substantially conical nose portion and a shank 62 upon which the cam head is mounted. The head 60 is positioned within the switch housing 30 adjacent the free ends of the clip sides 57 while the shank 62 projects radially outwardly from the housing through a bore in the housing sidewall, the entire cam actuator being reciprocable radially with respect to the housing. The outer end of the shank s2 bears against the spring pocket clasp 64, one end of which is positioned in a slot 66 in the sleeve 4-1 to secure the clasp to the flashlight. When the control switch is in open position, the cam head 60 is positioned in the space between the outwardly flared free ends 68 of the clip sides and the sidewall of the switch housing, Figure 3. When the clip sides 57 spring 4 inwardly to lock the switch in closed position, the cam head is pushed outwardly into engagement with the housing sidewall due to the convergence of the flared ends. Thereafter, if the cam head is pushed inwardly by exerting a positive pressure upon the upper end of the pocket clasp, the conical nose portion of the head will cam the clip sides apart and cause them to disengage from the shoulder on the plunger shaft so that the plunger element can return to open position under the influence of springs 54, 44.

With the above described arrangement the flashlight can be quickly and conveniently turned on and oh by simply pushing inwardly on the projecting finger piece 50 or the upper end of the clasp 64, both of which exert positive action on the control switch. If desired, the flashlight can also be used as a flasher or signalling light by holding the upper end of the clasp 64 in its in position and operating the finger piece alone to open and close the switch.

The flashlight may, if desired, be provided with a thin external sleeve 70 of some material such as vinyl plastic, the sleeve being positioned on the body member 11 adjacent the clasp 64 to facilitate the insertion and withdrawal of the light from the pocket.

This invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiment disclosed is therefor to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims.

What I claim is:

1. In a flashlight, a body member, a head secured to one end of said body member, resilient means within said head to secure a lamp bulb therein, a normally open control switch secured to the other end of said body member including a plunger element movable longitudinally into the body to close the switch, said element being formed with stop means thereon, a resilient clip positioned on said plunger element and engageable with said stop means to hold the element in switch closing position when the latter is moved into said body, and an independent cam actuator operable upon said clip to disengage it from said stop means and release said plunger element from switch closing position.

2. In a flashlight, a tubular body member, a head secured to one end of said body member, resilient means within said head to secure a lamp bulb therein, a normally open control switch secured to the other end of said body member including a plunger element movable longitudinally into the body to close the switch, said element being formed with a thickened portion terminating at one side in a shoulder, a substantially U-shaped resilient clip, the sides of said clip normally compressively engaging the thickened portion of said plunger element and springing inwardly into edgewise abutment with said shoulder to maintain the element in switch closing position when the latter is moved into said body, and in independent cam actuator operable upon the clip sides to spring them outwardly and permit said plunger element to be released from switch closing position.

3. In a flashlight including a dry cell and a lamp bulb, one dry cell terminal being electrically connected with one bulb terminal, a current conducting body member adapted to enclose said dry cell, a head secured to one end of said body member and making electrical connection therewith, a holder for said lamp bulb positioned within said head comprising a ring shaped member of resilient non-conducting material adapted to engage the base of the bulb, a plurality of wire staples passing through said ring shaped member to make electrical connection between the other bulb terminal and said head, a normally open control switch secured to the other end of said body member including a plunger element making electrical connection with the body member and a contact spaced from said plunger and making electrical connection with the other dry cell terminal, said plunger element being movable longitudinally into said body member to engage said contact thereby closing the switch and completing the circuit through the bulb and dry cell, said element being formed with a thickened portion terminating at one side in a shoulder, a substantially U- shaped resilient clip, the sides of said clip normally compressively engaging the thickened portion of said plunger element and springing inwardly into edgewise abutment with said shoulder to maintain the element in switch closing position when the latter is moved into said body, and an independent cam actuator operable upon the clip sides to spring them outwardly and permit said plunger element to be released from switch closing position.

4. In a device of the character described, a normally open control switch comprising a support member, a plunger element mounted for reeiprocable longitudinal movement within said member, a first movable contact mounted on said plunger element, a second movable contact normally spaced from said first contact, said first contact being moved into engagement with said second contact to close said switch when said plunger element is moved into said support member, said element being formed with adjacent cylindrical portions of unequal diameter having an annular shoulder therebetween, a substantially U-shaped resilient clip having inwardly biased sides whereby the free ends thereof tend to move into close proximity with one another, said clip sides being normally held apart by engagement with the larger diametered cylindrical portion of said element and springing inwardly into engagement with the smaller diametered portion thereof when the element is moved longitudinally into the support member, said clip sides moving into edgewise abutment with said shoulder during movement of the element to hold the latter in switch closing position, and an independent actuator adapted to cam the clip sides apart to disengage them from said shoulder and release said element from switch closing position.

5. In a flashlight, a body member, a head secured to one end of said body member, a lamp bulb holder positioned within said head comprising a ring shaped member of resilient non-conducting material adapted to engage the base of the bulb, current conducting means associated with said ring shaped member to make electrical connection between one bulb terminal and the remainder of the flashlight circuit, a normally open control switch secured to the other end of said body member including a plunger element movable longitudinally into the body to close the switch, said plunger element being formed with stop means thereon, a resilient clip engaging said plunger element and cooperable therewith to maintain the element in the switch closing posi tion, said clip being engageable with said stop means to maintain the plunger element in switch closing position when the latter is moved into said body member, and a single cam actuator operable upon said clip to release said plunger element from switch closing position.

6. In a flashlight including a dry cell and a lamp bulb, one dry cell terminal being electrically connected with one bulb terminal, a current conducting body member adapted to enclose said dry cell, a head secured to one end of said body member and making electrical connection therewith, a holder for said lamp bulb positioned within said head comprising a ring shaped member of resilient non-conducting material adapted to engage the base of the bulb, a plurality of current conducting elements passing through said ring shaped member to make electrical connection between the other bulb terminal and said head, a normally open control switch secured to the other end of said body member including a plunger element making electrical connection with the body member and a contact spaced from said plunger element and making electrical connection with the other dry cell terminal, said plunger element having stop means formed thereon and being movable longitutudinally into said body member to engage said contact thereby closing the switch and completing the circuit through the bulb and dry cell, a resilient clip engaging said plunger element and cooperable therewith to maintain the element in switch closing position, said clip being engageable with said stop means to maintain the plunger element in switch closing position when the latter is moved into said body member, and an independent cam actuator operable upon said clip to release said plunger element from switch closing position.

References Cited in the file of this patent UNITED STATES PATENTS 1,361,846 Gallagher Dec. 14, 1920 1,919,024 Abbotts July 18, 1933 1,995,141 Barber Mar. 19, 1935 2,273,360 Kidder Feb. 17, 1942 2,461,118 Lippencott Feb. 8, 1949 

